Woven twill textile fabric

ABSTRACT

An aspect of the present disclosure relates to a woven twill textile fabric, the fabric including: from about 90 to about 235 ends per inch warp cotton yarn; and from about 100 to about 2765 picks per inch multi-filament polyester weft yarn, wherein the picks are woven into the fabric in a single or in a group of at least two multi-filament polyester weft yarn, and wherein total content of cotton present in the fabric is at least about 50% by weight of the fabric, further wherein total thread count in the fabric ranges from about 190 to about 3000. The advantageous fabric realized in accordance with embodiments of the present disclosure can find utility as home textiles. Other aspects of the present disclosure relate to a method of manufacturing a draw textured yarn and a multi-ply separable draw textured yarn.

TECHNICAL FIELDS

The present disclosure pertains generally to the field of textile industry. In particular, the present disclosure provides a woven twill textile fabric that can find utility as home textile. The present disclosure also relates to a method of manufacturing a draw textured yarn and a multi-ply separable draw textured yarn.

BACKGROUND

Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.

A woven fabric is any textile formed by weaving and are often created on a loom, and made of many threads woven on a warp and a weft. Technically, a woven fabric is any fabric made by interlacing two or more threads at right angles to one another. These fabric only stretches diagonally on the bias directions (between the warp and weft directions), unless the threads used are elastic. So the properties of two or more threads that are woven together decide the characteristic of the end fabric. Hence, understanding and predicting the structure and properties of woven textiles is very important for achieving specific performance characteristics in various woven applications.

Textiles that may come in contact with the human skin for example underwear, towels, T-shirts etc. should be comfortable to human being. One easy way of achieving the same is to use cotton as a fabric material. Cotton has high breathability, absorbency, softness and is comfortable to wear. However, cotton may not be sturdy when utilized for making fabric that is used in tough environments such as heavy duty washing machine etc.

To overcome such limitations cotton yarns can be woven in combination with other synthetic fibers. Further, decreasing the denier of the textile fiber may also increase the comfort. Utilization of these fine yarns may increase the thread count of the fabric. An increased thread count represents the superiority of a textile over other textile fabric. However, fine synthetic yarns may break when fed into a loom apparatus. Hence, cotton-polyester hybrid weaves are limited to larger denier synthetic yarns that the loom may effectively use. Thus, the thread count, and the comfort, quality and lavishness associated therewith is limited.

Different combination of cotton and synthetics are tried conventionally to form a textile fabric with desired characteristic such as comfortable towards skin, breathability, strength and stretchability. Twisting the two yarns together prior to use as a single yarn in a weaving process also increases the sustainability of the yarn/fabric as it may increase the thread count to some extent. However, these yarns are still susceptible to break in a loom apparatus and the end fabric also exhibits low quality and comfortability.

There is, therefore, a need in the art to provide a comfortable, breathable, high strength, high quality cotton-polyester hybrid woven twill textile fabric that can find utility as home textile. The present disclosure satisfies the existing needs, as well as others and alleviates the shortcomings associated with conventional cotton-polyester hybrids.

OBJECTS OF THE INVENTION

An object of the present disclosure is to provide a woven textile fabric that overcomes the deficiencies associated with conventional woven textile fabric.

Another object of the present disclosure is to provide a woven twill textile fabric.

Another object of the present disclosure is to provide a woven twill textile fabric containing warp cotton yarn and multi-filament polyester weft yarn.

Another object of the present disclosure is to provide a woven twill textile fabric that is comfortable to human skin.

Another object of the present disclosure is to provide a woven twill textile fabric that can find utility as home textiles.

Another object of the present disclosure is to provide a method for manufacturing a draw textured yarn.

Another object of the present disclosure is to provide a method for manufacturing a multi-ply separable draw textured yarn.

Another object of the present disclosure is to provide a woven twill textile fabric that is easy to prepare.

Another object of the present disclosure is to provide a woven twill textile fabric that is cost-effective.

Another object of the present disclosure is to provide a woven twill textile fabric that is light-weight.

Another object of the present disclosure is to provide a woven twill textile fabric that is durable.

SUMMARY

The present disclosure pertains generally to the field of textile industry. In particular, the present disclosure provides a woven twill textile fabric that can find utility as home textile. The present disclosure also relates to a method of manufacturing a draw textured yarn and a multi-ply separable draw textured yarn.

An aspect of the present disclosure relates to a woven twill textile fabric, the fabric including: from 90 to 235 ends per inch warp cotton yarn; and from 100 to 2765 picks per inch multi-filament polyester weft yarn, wherein the picks are woven into the fabric in a single or in a group of at least two multi-filament polyester weft yarn, and wherein total content of cotton present in the fabric is at least about 50% by weight of the fabric, further wherein total thread count in the fabric ranges from about 190 to about 3000.

In an embodiment, cotton content in the warp cotton yarn is 100%. In an embodiment, the warp cotton yarn is a blend of cotton and any or a combination of a synthetic fiber and a natural fiber, wherein content of cotton in the blend is at least 90%.

In an embodiment, the multi-filament polyester weft yarn is a texturized yarn, and wherein the texturized yarn is a draw textured yarn. In an embodiment, the polyester weft yarn has a denier ranging from 7 to 24. In an embodiment, the polyester weft yarns are wound on a multi-pick yarn package at a type A shore hardness ranging from 65 to 80. In an embodiment, the polyester weft yarns are wound on the multi-pick yarn package at an angle ranging from 15 degrees to 25 degrees. In an embodiment, the number of filaments in the polyester weft yarn ranges from 4 to 24. In an embodiment, the filaments in the weft yarn are partially oriented, medium oriented or fully oriented.

Another aspect of the present disclosure relates to a method of manufacturing a draw textured yarn, the method including the steps of: passing a polymer melt through a spinning unit to form a plurality of molten streams; cooling the plurality of molten streams in a quenching zone to form a plurality of polymer filaments; grouping the polymer filaments to form a yarn; passing the yarn through at least one interlacing unit for interlacing the filaments within the yarn by adjusting the interlacing parameters to provide a separable interlaced filament yarn; and retaining the interlacing of the filaments within the yarn during further processing of the yarn to fabric.

In an embodiment, the separable interlaced filament yarn plies are separable from other yarn plies in the fabric. In an embodiment, two or more separable interlaced filament yarns are converged to form a multi-ply separable interlaced filament yarn.

Still another aspect of the present disclosure relates to a method of manufacturing a multi-ply separable draw textured yarn, the method comprising any of: (a) passing two or more interlaced yarns through a texturizing spindle; (b) passing at least one multi-ply separable interlaced filament yarn through a texturizing spindle, wherein the at least one multi-ply separable interlaced yarn is separable into at least two interlaced yarns; and (c) passing a combination of at least one multi-ply separable yarn and at least one interlaced yarn through a texturizing spindle, wherein the multi-ply separable yarn is separable into at least two interlaced yarns to provide the multi-ply separable draw textured yarn, wherein the multi-ply separable draw textured yarn is separable into at least two separable draw textured yarn, and wherein interlacing of filaments within the separable draw textured yarn is retained during further processing of the yarn to fabric and in the fabric so that ply of said separable draw textured yarn is separable from one other yarn plies in the fabric. In an embodiment, at least one multi-ply separable draw textured yarn is converged with at least one multi-ply separable draw textured yarn to increase the number of plies.

Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.

FIG. 1 illustrates an exemplary sectional image depicting the twill fabric construction, in accordance with an embodiment of the present disclosure.

FIG. 2 illustrates an exemplary flow chart depicting a method for manufacturing a draw textured yarn, in accordance with an embodiment of the present disclosure.

FIG. 3 illustrates an exemplary flow chart depicting a method for manufacturing a multi-ply separable draw textured yarn, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION

The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.

Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the “invention” may in some cases refer to certain specific embodiments only. In other cases it will be recognized that references to the “invention” will refer to subject matter recited in one or more, but not necessarily all, of the claims.

As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.

All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.

Various terms as used herein are shown below. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.

The present disclosure pertains generally to the field of textile industry. In particular, the present disclosure provides a woven twill textile fabric that can find utility as home textile. The present disclosure also relates to a method of manufacturing a draw textured yarn and a multi-ply separable draw textured yarn.

An aspect of the present disclosure relates to a woven twill textile fabric, the fabric including: from 90 to 235 ends per inch warp cotton yarn; and from 100 to 2765 picks per inch multi-filament polyester weft yarn, wherein the picks are woven into the fabric in a single or in a group of at least two multi-filament polyester weft yarn, and wherein total content of cotton present in the fabric is at least about 50% by weight of the fabric, further wherein total thread count in the fabric ranges from about 190 to about 3000. The advantageous fabric realized in accordance with embodiments of the present disclosure can find utility as home textiles.

In an embodiment, cotton content in the warp cotton yarn is about 100%. In an embodiment, the warp cotton yarn is a blend of cotton and any or a combination of a synthetic fiber and a natural fiber. In an embodiment, the warp cotton yarn is a blend of cotton and any or a combination of a synthetic fiber and a natural fiber, wherein content of cotton in the blend is at least about 90%.

In an embodiment, the multi-filament polyester weft yarn is a texturized yarn. In an embodiment, the texturized yarn is a draw textured yarn. In an embodiment, the polyester weft yarn has a denier ranging from 7 to 24. In an embodiment, the polyester weft yarns are wound on a multi-pick yarn package at a type A shore hardness ranging from 65 to 80. In an embodiment, the polyester weft yarns are wound on the multi-pick yarn package at an angle ranging from 15 degrees to 25 degrees. In an embodiment, the number of filaments in the polyester weft yarn ranges from 4 to 24. In an embodiment, the filaments in the weft yarn are partially oriented, medium oriented or fully oriented.

FIG. 1 illustrates an exemplary sectional image depicting the twill fabric construction, in accordance with an embodiment of the present disclosure. As can be seen in FIG. 1 a twill weave is formed by passing the weft yarn under and over multiple warp yarns (black colored in FIG. 1), in an alternating sequence that creates a diagonal ribbed pattern on the fabric's surface. The diagonal lines can runs either right or left on the fabric face.

Another aspect of the present disclosure relates to a method of manufacturing a draw textured yarn, the method including the steps of: passing a polymer melt through a spinning unit to form a plurality of molten streams; cooling the plurality of molten streams in a quenching zone to form a plurality of polymer filaments; grouping the polymer filaments to form a yarn; passing the yarn through at least one interlacing unit for interlacing the filaments within the yarn by adjusting the interlacing parameters to provide a separable interlaced filament yarn; and retaining the interlacing of the filaments within the yarn during further processing of the yarn to fabric. In an embodiment, two or more separable interlaced filament yarns are converged to form a multi-ply separable interlaced filament yarn. In an embodiment, the separable interlaced filament yarn plies are separable from other yarn plies in the fabric. FIG. 2 illustrates an exemplary flow chart (200) depicting a method for manufacturing a draw textured yarn, in accordance with an embodiment of the present disclosure. As can be read in FIG. 2, the method of manufacturing the draw textured yarn includes the steps of: passing a polymer melt through a spinning unit to form a plurality of molten streams, as shown at 202; cooling the plurality of molten streams in a quenching zone to form a plurality of polymer filaments, as shown at 204; grouping the plurality of polymer filaments to form a yarn as shown at 206; passing the yarn through at least one interlacing unit for interlacing the filaments within the yarn by adjusting the interlacing parameters to provide a separable interlaced filament yarn as shown at 208; and retaining the interlacing of the filaments within the yarn during further processing of the yarn to form a fabric, as shown at 210.

Still another aspect of the present disclosure relates to a method of manufacturing a multi-ply separable draw textured yarn, the method comprising any of: (a) passing two or more interlaced yarns through a texturizing spindle; (b) passing at least one multi-ply separable interlaced filament yarn through a texturizing spindle, wherein the at least one multi-ply separable interlaced yarn is separable into at least two interlaced yarns; and (c) passing a combination of at least one multi-ply separable yarn and at least one interlaced yarn through a texturizing spindle, wherein the multi-ply separable yarn is separable into at least two interlaced yarns to provide the multi-ply separable draw textured yarn, wherein the multi-ply separable draw textured yarn is separable into at least two separable draw textured yarn, and wherein interlacing of filaments within the separable draw textured yarn is retained during further processing of the yarn to fabric and in the fabric so that ply of said separable draw textured yarn is separable from one other yarn plies in the fabric. In an embodiment, at least one multi-ply separable draw textured yarn is converged with at least one multi-ply separable draw textured yarn to increase the number of plies.

FIG. 3 illustrates an exemplary flow chart depicting a method of manufacturing (300) a multi-ply separable draw textured yarn, in accordance with an embodiment of the present disclosure. As can be seen from FIG. 3, method of manufacturing the multi-ply separable draw textured yarn (300) includes steps of: (302) passing at least one multi-ply separable interlaced filament yarn through a texturizing spindle to form a multi-ply separable draw textured yarn (304). Alternatively, two or more interlaced yarns can be passing through a texturizing spindle to realize the multi-ply separable draw textured yarn. Alternatively, a combination of at least one multi-ply separable yarn and at least one interlaced yarn can be passed through a texturizing spindle to realize the multi-ply separable draw textured yarn, wherein the multi-ply separable yarn is separable into at least two interlaced yarns to provide the multi-ply separable draw textured yarn.

While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

Advantages of the Invention

The present disclosure provides a woven textile fabric that can overcome the deficiencies associated with the conventional woven textile fabric.

The present disclosure provides a woven twill textile fabric.

The present disclosure provides a woven twill textile fabric containing warp cotton yarn and multi-filament polyester weft yarn.

The present disclosure provides a woven twill textile fabric comfortable to human skin.

The present disclosure provides a woven twill textile fabric that can find utility as home textiles

The present disclosure provides a method for manufacturing the draw textured yarn.

The present disclosure provides a method for manufacturing a multi-ply separable draw textured yarn

The present disclosure provides a woven twill textile fabric that is easy to prepare.

The present disclosure provides a woven twill textile fabric that is cost-effective.

The present disclosure provides a woven twill textile fabric that is light-weight.

The present disclosure provides a woven twill textile fabric that is durable. 

I claim:
 1. A woven twill textile fabric, the fabric comprising: from 90 to 235 ends per inch warp cotton yarn; and from 100 to 2765 picks per inch multi-filament polyester weft yarn, wherein the picks are woven into the fabric in a single or in a group of at least two multi-filament polyester weft yarn, and wherein total content of cotton present in the fabric is at least about 50% by weight of the fabric, further wherein total thread count in the fabric ranges from about 190 to about
 3000. 2. The fabric as claimed in claim 1, wherein cotton content in the warp cotton yarn is 100%.
 3. The fabric as claimed in claim 1, wherein the warp cotton yarn is a blend of cotton and any or a combination of a synthetic fiber and a natural fiber, wherein content of cotton in the blend is at least 90%.
 4. The fabric as claimed in claim 1, wherein the multi-filament polyester weft yarn is a texturized yarn, and wherein the texturized yarn is a draw textured yarn.
 5. The fabric as claimed in claim 1, wherein the polyester weft yarn has a denier ranging from 7 to
 24. 6. The fabric as claimed in claim 1, wherein the polyester weft yarns are wound on a multi-pick yarn package at a type A shore hardness ranging from 65 to
 80. 7. The fabric as claimed in claim 1, wherein the polyester weft yarns are wound on the multi-pick yarn package at an angle ranging from 15 degrees to 25 degrees.
 8. The fabric as claimed in claim 1, wherein the number of filaments in the polyester weft yarn ranges from 4 to
 24. 9. The fabric as claimed in claim 1, wherein the filaments in the weft yarn are partially oriented, medium oriented or fully oriented.
 10. A method of manufacturing a draw textured yarn, the method comprising the steps of: passing a polymer melt through a spinning unit to form a plurality of molten streams; cooling the plurality of molten streams in a quenching zone to form a plurality of polymer filaments; grouping the polymer filaments to form a yarn; passing the yarn through at least one interlacing unit for interlacing the filaments within the yarn by adjusting the interlacing parameters to provide a separable interlaced filament yarn; and retaining the interlacing of the filaments within the yarn during further processing of the yarn to fabric.
 11. The method as claimed in claim 10, wherein the separable interlaced filament yarn plies are separable from other yarn plies in the fabric.
 12. The method as claimed in claim 10, wherein two or more separable interlaced filament yarns are converged to form a multi-ply separable interlaced filament yarn.
 13. A method of manufacturing a multi-ply separable draw textured yarn, the method comprising any of: (a) passing two or more interlaced yarns through a texturizing spindle; (b) passing at least one multi-ply separable interlaced filament yarn through a texturizing spindle, wherein the at least one multi-ply separable interlaced yarn is separable into at least two interlaced yarns; and (c) passing a combination of at least one multi-ply separable yarn and at least one interlaced yarn through a texturizing spindle, wherein the multi-ply separable yarn is separable into at least two interlaced yarns to provide the multi-ply separable draw textured yarn, wherein the multi-ply separable draw textured yarn is separable into at least two separable draw textured yarn, and wherein interlacing of filaments within the separable draw textured yarn is retained during further processing of the yarn to fabric and in the fabric so that ply of said separable draw textured yarn is separable from one other yarn plies in the fabric.
 14. The method as claimed in claim 13, wherein at least one multi-ply separable draw textured yarn is converged with at least one multi-ply separable draw textured yarn to increase the number of plies. 